Process for and processor of natural gas and activated carbon together with blower

ABSTRACT

A method of and device for processing carbonacious material into gas and activated carbon together with blower.

CROSS REFERENCE OF RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 12/590,391 (the '391 application), filed Nov. 5, 2009 entitled PROCESS FOR AND PROCESSOR OF NATURAL GAS AND ACTIVATED CARBON TOGETHER WITH BLOWER, which is a continuation of U.S. application Ser. No. 12/291,188 (the '188 application), filed Nov. 6, 2008 entitled FLOW RATE OF GAS IN FLUIDIZED BED DURING CONVERSION OF CARBON BASED MATERIAL TO NATURAL GAS AND ACTIVATED CARBON and claims priority therefrom. The '188 application claims benefit of U.S. Provisional Patent Application 61/004,082, filed Nov. 23, 2007 entitled CLOSED LOOP FLUIDIZED BED FLASH GASIFICATION SYSTEM and U.S. Provisional Patent Application 61/137,213, filed Jul. 28, 2008 entitled LIQUIFACTION PROCESS FOR CHANGING ACTIVATED CARBON AND SYNGAS INTO DIESEL FUEL. All of the above applications are incorporated herein by reference as if fully set forth herein.

FIELD OF THE INVENTION

The present invention relates to fluid flow beds used in the process of converting carbon based matter into natural gas and activated carbon and more particularly related to the rate of fluid flow.

BACKGROUND OF THE INVENTION

Coal has long been used as a source of fuel. As the search for alternative fuels increases, several inventors have been looking toward further developing technology related to the use of coal. These inventors have come to recognize that the natural gas found in coal is not limited to coal, but rather is found in various forms of man-made and naturally occurring substances including, but not limited to municipal solid waste, sewage, wood waste, biomass, paper, plastics, hazardous waste, tar, pitch, activated sludge, rubber tires and oil-based residue.

The question has generally not been where one should look for natural gas, but rather how to liberate the natural gas. This has led to several different confined gasification liquefaction techniques. These systems in general terms include the down draft gasification, updraft gasification, and fluidized bed gasification.

The down draft gasification, also called a “co-current configuration system”, relies on gravity to move the feedstock, which perhaps is coal. The ignition system flows with the feedstock with resultant ash or slag falling out the bottom. The ash or slag is hazardous waste and is treated as such. This system of partial combustion yields a low BTU gas that must undergo extensive cleaning.

The updraft gasification, also called a “countercurrent system”, uses a blower to direct the feedstock up through the system. The combustion source is generally directed in an opposite direction to the feedstock or perpendicular to it. The ash and slag falls out the bottom where it is collected as hazardous waste. This is a partial combustion system that results in low BTU gas and tars that must be cleaned prior to use.

The conventional fluidized bed uses sand, char or some combination thereof. The fluid, usually air or steam, is directed through the sand, to the feedstock thereabove. The environment is usually oxygen starved resulting in partial combustion. The temperatures are relatively low resulting in low BTU gas that must be extensively cleaned prior to use. The ash is corrosive, invoking the use of limestone to minimize the corrosive effect. Some examples of the fluidized bed technology follow:

Giglio (U.S. Patent Application 2006/0130401) discloses a method of co-producing activated carbon in a circulating fluidized bed gasification process. The carbonacious material is treated in a fluidized bed to form syngas and char. (¶14) In a subsequent step, the char is turned to activated carbon with steam and carbon dioxide. Giglio teaches using the activated carbon to clean the syngas and separation of the gas and activated carbon. The cleaned syngas and solids are separated in a dust. Giglio uses a separator to separate the activated carbon and natural gas from the feedstock. That is, the gaseous flows through the fluidized bed are not used to separate components of carbonacious material on the basis of density.

Jha et al. (U.S. Pat. No. 5,187,141) discloses a process for the manufacture of activated carbon from coal by mild gasification and hydrogenation. The coal is first heated to a temperature between evaporation of water and below removal of volitilization. The dry coal is the heated in a mostly non-oxygenous atmosphere to volatilize and remove the contained volatile matter and produce char. In a second step, the char is subjected to a hydrogenation process to activate the carbon. The gaseous flows through the fluidized bed are not used to separate components of carbonacious material on the basis of density.

Ueno et al. (United States Patent Application 2003/0027088) discloses a method for treating combustible wastes. Combustible wastes includes paper, plastics, coal, tar, pitch, activated sludge, and oil-based residue. ¶8. The combustible wastes are carbonized at a temperature of around 400-600 degrees C. The carbonized material is then subjected to a temperature around 1000-1300 degrees C. in an inert atmosphere. This drives off the volatiles and may activate the carbon. The carbonized product is blown into exhaust gas, e.g., volatiles, to purify the exhaust gas. (Exhaust gas is preferred to be from refuse incineration, electric power plants, steel-making electric furnace, scrap melting furnace, and sintering machine.). The volatiles are used as a heat source for the carbonization step, although they are acknowledged to have harmful substances contained therein. ¶40.

The rate of fluid flow has generally not been discussed nor has the benefits of the fluid flow rate been considered. What is needed is a flow rate of gas in fluidized bed during conversion of carbon based material to natural gas and activated carbon that yields beneficial results that extend beyond the speed of combustion or conversion. Desirably, the flow rate separates material desired to be suspended above the fluidized bed from the material not desired to be above the bed.

SUMMARY OF THE INVENTION

The present method of processing carbonacious material into natural gas and activated carbon may include the steps of: placing feedstock onto a fluidized bed; directing non-oxygenated gas through the fluidized bed; adjusting a velocity of the gas such that the gas is slow enough to leave the feedstock on the fluidized bed and fast enough to remove activated carbon and volatiles.

In a preferred method, the process may include the steps of placing feedstock onto a fluidized bed; directing superheated non-oxygenated gas through the fluidized bed; adjusting a velocity of the superheated gas such that the gas is slow enough to leave the feedstock on the fluidized bed and fast enough to remove activated carbon and volatiles; allowing cleaning of the volatiles using the activated carbon to form clean natural gas and activated carbon; separating the natural gas and the activated carbon; recycling a portion of the natural gas back to the fluidized bed; collecting a non-recycled portion of the natural gas; and collecting the activated carbon.

Advantageously, the plenum leading away from the fluidized bed may be in an elevated position from the fluidized bed, permitting immediate co-mingling of the volatiles with the activated carbon yielding clean natural gas and activated carbon.

As yet another advantage, the velocity keeps the fluidized bed with a fresh supply of carbonacious material and self purges the processed materials from the fluidized bed.

As still yet another advantage, the process is completely devoid of water and oxygen, which leads to partial combustion, e.g. charring, or complete combustion, e.g. ash, and thus allowing the carbonacious material to proceed directly to activated carbon.

As still yet another advantage, the velocity operates as a gravity separator relying on the change in density between the feedstock and mixture of activated carbon and volatiles.

These and other advantages will become clear from reading the below description with reference to the appended drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart showing the present inventive method;

FIG. 2 is a block diagram showing the present inventive apparatus;

FIG. 3 is a flow chart showing the first process of the present inventive method;

FIG. 4 is a diagram showing the first processor of the present invention;

FIG. 5 is a plan view of the fluidized bed of the first processor;

FIG. 6 is a schematic drawing of the airlock of the first processor;

FIG. 7 is a side view in partial phantom showing the blower assembly and seal assembly of the present invention;

FIG. 8 is a top or bottom view of the housing assembly of the blower of the present invention;

FIG. 9 is a bottom view of the seal assembly of the blower of the present invention;

FIG. 10 is a top view of the seal assembly of the blower of the present invention;

FIG. 11 is a right side portion of a partial cross-sectional view of the housing and blower assemblies of the present invention taken along the lines 11 a-11 a and 11 b-11 b of FIG. 7.

FIG. 12 is a flow chart showing the second process of the present invention; and

FIG. 13 is a schematic drawing showing the various components of the second processor of the present invention.

The figures are presented as being the best mode of the present invention and are not to be deemed limiting in any regard.

DETAILED DESCRIPTION Definitions

The following terms, defined immediately below, have such meanings throughout the description and claims:

Activated carbon—a porous crystalline structure made primarily of hydrogen deficient carbon. The carbon-to-carbon bonding within the activated carbon may be varied, including single, double, triple and quadruple bonds structured in chains and rings and may include monomers and polymers randomly found in and throughout the activated carbon. Activated carbon is not achieved through an intermediate step involving char or ash or arrived at through combustion.

Activated char—not truly activated carbon, but rather an amorphous carbon compound. Activated char may have an intermediary step of charring and involves partial combustion.

Amorphous carbon—a carbon compound with no particular structural arrangement. Amorphous carbon may be hydrogenated or may be at a hydrogen deficit.

Char—Char is an amorphous carbon structure substantially hydrogen deficient. Char is often found as a by-product of incomplete combustion of organic compounds including fossil fuels and biomass due to a partial deprivation of oxygen.

Crystalline carbon—a carbon compound with a definite structure. Crystalline carbon may be fully hydrogenated or substantially devoid of hydrogen. Crystalline carbon and amorphous carbon as used herein are opposite terms.

Diesel—a fuel that may be represented by the chemical formula C12H23, on average, but is a mixture of hydrocarbons generally between C10H20 to C15H28.

Feedstock—any carbon based material, preferably, but not limited to coal and activated carbon. The feedstock should be dried and may have a diameter range between 1/16 and ⅝ inches and a preferred diameter range of between ⅛ and ¼ inch when used in the preferred mode.

Gas—one of the three states of matter and does not necessarily denote the combustible matter. This invention is intended to be used in the production of combustible gas and where combustible gas is intended term the term combustible, natural, diesel or other such distinguishing term will be used.

Hydrogen deficient carbon—carbon compounds that lack sufficient hydrogen to convert to diesel without hydrogenation.

Natural gas—Combustable material driven off of feedstock or manufactured from carbon chains shorter, e.g. methane and ethane, than used in diesel fuel. Natural gas is used within the ordinary and common use of the term.

Volatiles—gaseous material driven off of feedstock, which is generally combustible. While possible that trace amounts of non-combustable material may be included in the volatiles, the levels may be trace or less. (None were found upon testing.) The components in testable quantities of first volatiles were entirely clean natural gas. The first volatiles are generally are 90+% methane with the balance being slightly longer hydrocarbons. The second volatiles are presently not determined, but are understood to contain natural gas and hydrocarbons longer than natural gas and shorter than diesel.

Detailed Description—Overview

The present invention is most readily understood in components, but may be joined, integral or otherwise, into a comprehensive whole apparatus 10. Fully described below are components including first processor 130, blower 210 and second processor 410 together with their respective manners of operation. In combination, these components 130, 210, and 410 process feedstock 12 into diesel fuel 14 and natural gas 16. Intermediary by-product, including natural gas 16 and activated carbon 18 may optionally be collected in user determined amounts. Under this section, description—overview, is a look at the overall process and is supported by the first processor, blower and second processor descriptions below.

Numerals as used throughout are in part determined by the component in which the numeral is used. The part numbers are two digit when the numeral is selected for description of the entire apparatus 10, part numbers are three digit with a leading 1 when referring to first processor 130, part numbers are three digit with a leading 2 when referring to the blower 210, and part numbers are three digit with a leading 4 when referring to second processor 410. Components such as activated carbon, natural gas and others have multiple numbers with the leading digit indicating the section in which the component is being discussed and the two digit corresponding to the other arts within the appropriate section.

The present inventive method of manufacturing diesel, may include the steps of providing a feedstock 12, step 30 of FIG. 1; processing the feedstock 12 to produce hydrogen deficient carbon material 20 and first volatiles 24, step 32; hydrogenating the hydrogen deficient carbon material 20, step 34; and processing the hydrogenated hydrogen deficient carbon material 20 into second volatiles 26 and diesel 14, step 36.

Stated in differently, in breadth and terms, the present method of manufacturing diesel, preferably includes the steps of: providing a feedstock 12 having a hydrogen deficient carbon material 20; and processing the hydrogen deficient carbon material 20 into a mixture of volatiles 22 and diesel 14. Included may be intermediary steps of: processing the feedstock 12 into a mixture of first volatiles 24 and hydrogen deficient carbon material 20; and processing the hydrogen deficient carbon material 20 into a mixture of second volatiles 26 and diesel 14. The mixture of first volatiles 24 and hydrogen deficient carbon material 20 may be a mixture of natural gas 16 and activated carbon 18, whereas the mixture of second volatiles 26 and diesel 14 may include natural gas 16, hydrocarbons longer than natural gas 16 and shorter than diesel 14 and diesel 14.

The feedstock 12 may be selected from the group of coal, activated carbon, char, biomass and other carbon based matter. The hydrogen deficient carbon material 20 typically is activated carbon 18, but may be carbon in any crystalline, amorphous or combined configuration, including, but not limited to various chars. The first volatiles 24 preferably is natural gas 16. The second volatiles 26, while including natural gas 16, includes hydrocarbons longer than natural gas 16.

The present apparatus 10 for manufacturing diesel 14 may include a feedstock 12; a first processor 130, the processor 130 being adapted to convert the feedstock 12 into a mixture of hydrogen deficient carbon material 20 and volatiles 22. A blower 210 preferably is in fluid communication with the feedstock 12 and adjusted to separate the feedstock 12 from hydrogen deficient carbon material 20 and volatiles 22. The blower 210 desirably is positioned partially within the first processor 130 and partially outside the first processor 130. Optionally, a second processor 410 may be operably joined to the first processor 210 and adapted to convert hydrogen deficient carbon material 20 into a mixture of diesel 14 and volatiles 22.

Stated differently, in breadth and terms, the apparatus 10 for manufacturing diesel 14 may include a feedstock 12 having hydrogen deficient carbon material 20 and a processor 410 adapted to convert the hydrogen deficient carbon material 20 into a mixture of diesel 14 and volatiles 22.

Detailed Description—First Process/Processor

Reference numerals 110-126 are reserved for process steps and are found on the flow chart designated as FIG. 3. Numerals 130 through 300 are reserved for apparatus components and are found on FIG. 4 through FIG. 6.

The present method of processing feedstock 134 into first volatiles 154 and hydrogen deficient carbon material 157 may have a first step 110 of selecting a feedstock 134 as shown in FIG. 3. Suitable material from which to generate feedstock 134 includes, but is not limited to, coal, municipal solid waste, sewage, wood waste, biomass, paper, plastics, hazardous waste, tar, pitch, activated sludge, rubber tires and oil-based residue. Coal is the preferred feedstock. The grade of coal is not significant, since this is not a process involving partial or complete combustion. However, wet material, including coal, should be dried.

The feedstock 134 is then placed onto a fluidized bed 144, signified on FIG. 3 as step 112. This step preferably is done in a controlled manner to preclude oxygen and/or water from entering with the feedstock 134. For instance, the feedstock 134 may enter through an airlock system 135.

The airlock system 135 may include a feed hopper 136, a screw auger 138, a rotary airlock 140, and a slide gate 142 with a sleeve 142 a and aperture 142 b. Feedstock 134 from the feed hopper 136 is directed by the screw auger 138 to the rotary airlock 140. Rotating the rotary airlock 140 drops feed stock 134 into the aperture 142 b of the slide gate 142. Oscillation of the slide gate 142 through the sleeve 142 a directs the feedstock 134 over the chute 184, whereupon the feedstock 134 falls onto the fluidized bed 144. The feedstock 134 encounters a slightly elevated atmospheric pressure as it reaches the chute 184. This pressurized atmospheric assures that any airflow through the air lock system 135 is in an outward direction, not inward. Other airlock systems are known to those of ordinary skill in the art and may be used in lieu of the disclosed airlock system 135.

The feedstock 134 is suspended in the superheated natural gas 149 of the fluidized bed 144. The feedstock 134 suspended on the fluidized bed 144 is done in such manner that the feedstock 134 is supported by matter that is in a gaseous state, e.g., the superheated natural gas 149. Feedstock 134 is floated in a gaseous stream. Superheated gas 149 directed at the feedstock 134 forms the gaseous stream and is the preferred matter that is in the gaseous state.

Superheated natural gas 149 is directed, see 114 on FIG. 3, through the fluidized bed 144, which converts the feedstock 134 into first volatiles 154 and hydrogen deficient carbon 157. The hydrogen deficient carbon 157 preferably is activated carbon 156 and what is stated as to activated carbon 156 applies to hydrogen deficient carbon 157. The temperature needs to be selected in consideration of the feedstock size, since the volatiles 154 should all be released sufficiently fast to activate the carbon. The feedstock 134 should be between 1/16 and ⅝ inches in diameter and preferably the size is between ⅛ and ¼ inches in diameter. This may be referred to as flash heating. The superheated natural gas 149 is clean, and may be natural gas 149 obtained from this disclosed process, herein referred to as recycled. The superheated natural gas 149 may be heated to a temperature between 1000 degrees F. and 1500 degrees F. and preferably is between 1000 degrees and 1200 degrees F. These temperatures are found desirable in that they flash heat the feedstock 134, driving off the volatiles rapidly e.g., seconds. The rapid vaporization, expansion, of the volatiles 154 activates the carbon.

The velocity, see element 116 of FIG. 3, of the superheated natural gas 149 is adjusted such that the natural gas 149 is slow enough to leave the feedstock 134 on the fluidized bed 144 and fast enough to remove a mixture of activated carbon 156 and volatiles 154. The velocity separates the feedstock 134, activated carbon 156 and volatiles 154 based on density of the material, e.g. less dense material blows away (in a controlled manner). Feedstock 134 is more dense than activated carbon 156, which is more dense than volatiles 154. The velocity of the gas flow is thus set to move the less dense material, e.g. mixture of volatiles 154 and activated carbon 156 into a first plenum 152, allowing the feedstock 134 to remain on the fluidized bed 144 for further processing. The velocity is slow enough so as to not remove the feedstock 134. As the fluidized bed 144 continues to separate the volatiles 154 from the feedstock 134, the feedstock 134 converts directly to activated carbon 156 without an intermediary step of charring. The system, devoid of oxygen, does not have partial or complete combustion and thus does not form char or ash. The flow rate depends on the size of the fluidized bed. A very small bed may have a flow rate of 10 cubic feet per minute, while a very large bed may have a rate of 20,000 cubic feet per minute. Desirably, the velocity is between 5500 and 6500 cubic feet per minute and most preferably is approximately 6000 cubic feet per minute.

A displacer 182 may be positioned in the chute 184, perhaps vertically ocsillatable, may be used to adjust the size of the open area that is the fluidized bed 144. This in turn increases the velocity of the natural gas 149, assuming the overall flow rate, e.g., volume moved, remains unchanged. The displacer 182 beneficially allows for more efficient carbon removal from the fluidized bed 144 and keeps the fluidized bed 144 cleaner. In practice, a displacer 182 performs with better results than altering the velocity through the use of increased performance from one or more blowers 168. The preferred blower 168 is as described below in the section titled Description—Blower.

The activated carbon 156 and volatiles 154 are co-mingled from the fluidized bed 144 until the vortex separator 158 as will be discussed, see element 118 of FIG. 3. The activated carbon 156 in the mixture (or co-mingled collection) of volatiles 154 and activated carbon 156 is allowed to clean the volatiles 154 to form clean natural gas 149 and activated carbon 156. Harmful compounds, such as mercury, chlorine and sulfur compounds, gather in, are collected by and are stored in the activated carbon 156. The harmful compounds found in feedstock 134, commonly coal, are only known to liberate under conditions of combustion or application of a strong acid, neither one of which is found in the present invention. Accordingly, it is believed that harmful compounds do not liberate from the feedstock 134 and remain in the activated carbon 156 never being part of the volatiles 154. Testing on the current process has not shown any harmful compounds to be in the volatiles 154 and that the volatiles 154 leaving the fluidized bed 144 are clean natural gas 149. It should be noted that feedstocks 134 may have combustable gases that would be volatiles 154, but be longer carbon chains than natural gas 149. Cleaning, however, is allowed to occur to the extent any harmful substances do liberate. Cleaning the volatiles 154 using the activated carbon 156 to form clean natural gas 149 and activated carbon 156, may start at least as early as when the volatiles 154 and activated carbon 156 are leaving the fluidized bed 144, with the cleaning process continuing through completion.

The activated carbon 156 is separated from the natural gas 149 in a vortex separator 158, see element 120 of FIG. 3. The vortex separator 158 is of the size and manner known to one skilled in the art. The natural gas 149 may be drawn by a blower 168 through a second plenum 162 attached to the vortex separator 158, while the activated carbon 156 settles out the bottom of the separator 158. The resultant natural gas 149 is medium BTU natural gas, (1000 Btu/SCF). The activated carbon 156 collected at the bottom of the vortex separator 158 may be cooled, screened, graded/processed and packaged for sale or may remain heated and be used in the second processor 410 as will be described below. The activated carbon 156 ranges in size between a powder to ¼ inch diameter. The activated carbon 156 may be cooled in sealed cooling conveyors.

In a step of recycling 122 of FIG. 3, a portion, perhaps 10%, of the natural gas 149 may be recycled back to the fluidized bed 144 and a portion, perhaps 5% or less, may go to be recycled to a burner 180 for combustion that is used to superheat the gas for the fluidized bed 144. The non-recycled portion of the natural gas 149 may be collected as shown in step 124 of FIG. 3. Collecting 124 may include cooling, compressing and packaging the natural gas for sale. The activated carbon 156 collected at the bottom of the vortex separator 158 may be packaged for sale as identified in step 126 of FIG. 3.

Heretofore disclosed is a preferred method of processing feedstock 134 into natural gas 149 and activated carbon 156. The process is not a burning or partial burning process, but rather a temperature and density based separation process. Hereinafter described is the preferred apparatus 130 in which to carry out the disclosed process. Reference will be made to FIG. 4.

The processing apparatus 130 may have a feed hopper 136 joined to an airlock system 135. The airlock system 135 may have a screw auger 138, a rotary air lock 140, and a slide gate 142 positioned in a sleeve 142 a and defining an aperture 142 b. The screw auger 138 draws feedstock 134 from the feed hopper 136 and directs it into the rotary airlock 140. Turning the rotary airlock 140 drops feed stock 134 into the aperture 142 b of the slide 142. Oscillating the slide 142 in the slide 142 a, allows the feedstock 134 to drop through the aperture 142 b into the chute 184 and to the fluidized bed 144.

Alternative airlock systems 135 known to those of ordinary skill in the art may be used. No air or water is to pass beyond the airlock system 135. Either lead to combustion, which is not part of the present process.

Beyond the airlock 135, the feedstock 134 reaches the fluidized bed 144. Typically, a fluidized bed relies on sand or char as the bed through which the gas passes through. The present invention uses a metal grate 146 with small apertures 148 therethrough; the apertures 148 being smaller than the feedstock particles 134. The natural gas 149, alternative gases not involving oxygen may also be used, directed through the fluidized bed 144 is superheated to a temperature described above. The natural gas 149 may be directed through one or more bed conduits 151, the number of which is selected to keep the natural gas 149 moving at an even velocity substantially devoid of dead spots. The velocity, discussed supra, suspends the feedstock 134 and blows the volatiles 154 and activated carbon 156 into a first plenum 152. The feedstock 134 is positioned on the fluidized bed 144, while superheated natural gas 149 passes through the fluidized bed 144.

The natural gas 149 passing through the fluidized bed 144 has a velocity. The velocity is adjusted to a point such that the natural gas 149 is slow enough to leave the feedstock 134 on the fluidized bed 144 and fast enough to remove volatiles 154 and activated carbon 156. As such, the natural gas 149 flow is a separator of feedstock 134 from a mixture of activated carbon 156 and volatiles 154, such separation occurring on the basis of density.

The volatiles 154 and activated carbon 156 are allowed to co-mingle in the first plenum 152 to clean the volatiles 154, if any harmful compounds have been liberated, into clean natural gas 149. (Upon testing, no harmful compounds were found to have been liberated at any point during the process and in the apparatus described herein, thus the volatiles 154 were clean natural gas 149.) The plenum 152 is in fluid communication with the fluidized bed 144, being a receptor of a mixture of volatiles 154 and activated carbon 156 mixture therefrom. The first plenum 152, in fluid communication with the fluidized bed 144, may be positioned at a point elevated above the fluidized bed 144 and be sized and adapted to receive the volatiles 154 and activated carbon 156. Additional volatiles 154 are allowed to separate from the activated carbon 156 in the first plenum 152 which is maintained at or about the temperature of the fluidized bed 144.

The first plenum 152 empties into a vortex separator 158, which is a volatile/activated carbon separator 138. Preferably, the vortex separator 158 is heated to maintain the temperature of the natural gas 149. The vortex separator 138 separates the volatiles 154 (natural gas 149) from the activated carbon 156 based upon gravity. (Note: The volatiles 154, after co-mingling with activated carbon 156 in the first plenum 152, is clean natural gas 149 and, after the first plenum 152, volatiles 154 and natural gas 149 are interchangeable terms.) In essence, the activated carbon 156 falls out an aperture 160 in the bottom of the vortex separator 158. The volatiles 154 are drawn into a second plenum 162 designed for cooling, compressing, recycling, packaging natural gas as will now be described.

The second plenum 162 may include one or more blowers 168 positioned to maintain or adjust the velocity of the natural gas 149. The second plenum 162 joins to third and fourth plenums 164,166 respectively. A portion, perhaps 10%, of the natural gas 149 may be directed through the third plenum 164 to a heat exchanger 170 and back to the fluidized bed 144. (Insulation 147 may surround the fluidized bed 144 or the entire apparatus 130.) The heat exchanger 170 superheats the natural gas 149 prior to entry into the fluidized bed 144. The remaining natural gas 149, perhaps 90%, is directed into the fourth plenum 166 where it may interact with a heat exchanger 172 for cooling, a low pressure compressor 174 and bulk storage 176, ready for sale. A gas line 178 may lead from the bulk storage 176 to a burner 180 associated with the heat exchanger 170. The burner 180 combusts the natural gas 149 and provides heat to the heat exchanger 170. Post combustion gases, from the burner 180, may be directed up the stack 150.

The first processor and first process have been disclosed in a manner understandable to those of ordinary skill in the art with reference to figures, which form a part of the disclosure herein, describing the best mode of making and using the present invention as known to the inventor hereof. Those of ordinary skill in the art will discern alterations which may be made without departing from the spirit and scope of the present invention as set forth in the claims below.

Detailed Description—Blower

The present high temperature blower with environmental seal 210 may include a blower assembly 220, shaft 242, motor 246, housing assembly 260 and seal assembly 280. These components cooperate to form a blower 210 suitable for operation in high temperature environs where the blower 210 and motor 242 need to operate in separate atmospheres. These components will be discussed in serial fashion.

The blower assembly 220 may be any blower assembly known to those skilled in the art. Shown in FIG. 7 is a top plate 222 (also shown in FIG. 8), a bottom plate 224, a wrapper 226, outlet plate 228 and outlet 230, which cooperate to define a housing 232. The top plate 222 shown in FIG. 8 may be the same shape as the bottom plate 224. The housing 232 defines a chamber 234 in which the fan blades 236 move the gas in a cyclonic motion and direct the gas out through the outlet plate 228. Thus, gas may enter through an inlet 238, be accelerated and moved out through the outlet 230 defined in the outlet plate 228. Inside the housing 232, may be fan blades 236 and a spider 240.

The shaft 242 joins to the spider 240, which in turn is joined to the fan blades 236. The shaft 242 passes through a shaft opening 244 in the bottom plate 224 of the blower assembly 220, through the housing assembly 260 and the seal assembly 280, connecting to the motor 246. The motor 246 turns the shaft 242 thereby effecting movement of the fan blades 236 to direct gas in through the inlet 238 and out through the outlet 230. Various structural supports 248 may provide support between the blower assembly 220 and the motor 246. A bearing 250 may stabilize the shaft 242 relative to the motor 246. The housing assembly 260 is shown joined to the seal assembly 280, which in turn is joined to the bottom plate 224. A projection 252 on the seal assembly 280 may project into the blower assembly 220.

FIGS. 9-11 show the housing assembly 260 and seal assembly 280. As can be seen from FIGS. 9 and 10 the housing assembly 260 and seal assembly 280 are generally cylindrical, but may include protrusions that allow for bolts or other fasteners to pass therethrough.

Turning to FIG. 11, the housing assembly 260 may include an outer housing 262, which serves to encase a bearing 264. The bearing 264 may further include a bearing sleeve 266 that engages the shaft 242 on a side opposite a ball bearing 268. A grease port 270 preferably provides fluid communication with the ball bearing 268. The housing assembly 260 joins to the seal assembly 280 perhaps with fasteners 272.

It should be noted that the housing assembly 260 and seal assembly 280, being generally cylindrical are generally symmetrical, when looked at in cross section. To increase clarity, only one half of the cross section, e.g. one-quarter of the whole, is shown together with a portion of the shaft 242.

The seal assembly 280 may include a first housing portion 282 and a second housing portion 284 cooperatively define a coolant channel 286. O-rings 288,290, having differing diameters, provide a seal between the first and second housing portions 282,284. Ports, not shown, are preferred to be on opposite sides of the seal assembly 280. In this manner, coolant 292 may be directed into the coolant channel 286, flow around each side of the seal assembly 280 and out an exit port.

Positioned between the first and second housings 282,284 and the shaft 242 is a sleeve 294. The sleeve 294, which adds rotational support, rotates with the shaft 242 and has a collar 296 positioned at one end and inner gland 295 at the other end. The collar 296 is secured via a spacer 297 which may be fastened with at least one bolt 298 to the first housing 282. The inner gland 295 allows any heated gas that may pass through the shaft opening 244 to be received in a chamber 299. The chamber 299 is positioned adjacent the first and second housing portions 282,284 on a side opposite the coolant channel 286, thus defining a heat exchanger 300 therebetween. The gas within the chamber 299 remains relatively stagnant as there is no exit port and accordingly remains cooled by the coolant 292. Unintended exit ports are sealed with o-rings and oil in an outer gland, yet to be described.

A rubber o-ring 302, positioned in the sleeve 294, prevents gas that passed through the shaft opening 244 from further movement along the shaft 242. A gasket 304, preferably formed of graphfoil, prevents gas that passed through the shaft opening 244 from escape around the outside of the first and second housing portions 282,284. Thus, the o-ring 302 and gasket 304 preclude gas that passed through the shaft opening 244 from movement except into the chamber 299. The seals blocking escape of the gas from the chamber 299 are incorporated into the machined housing 306 for maintaining the sleeve 294.

The machined housing 306 maintains the sleeve 294 in alignment with the shaft 242 and seal assembly 280. Positioned adjacent the collar 296 is a lip seal 308. The lip seal 308 can be positioned in a void 310 containing oil 312 as a lubricant and as a seal to keep gas from the blower assembly 220 from escaping the seal assembly 280. The lip seal 308 rotatably secures one end of the sleeve 294. The oil 312 acts as a lubricant between parts that remain stationary relative to the seal assembly 280, such as the lip seal 308, and the components that rotate with the sleeve 294 as hereinafter described.

Moving from right to left, FIG. 11 shows a pin 314, which secures a mating ring 316 to the seal assembly 280. The mating ring 316 is preferred to be formed of silicon carbide for its strength, friction co-efficient and heat bearing properties. An o-ring 318 precludes gas from movement around the mating ring 316 further sealing the chamber 299. The lip seal 308, the pin 314, and the mating ring 316 do not rotate with the sleeve 294 and accordingly are lubricated with oil 312.

Spring 320 is shown biased against and between a retainer 322 and a disc 324. The disc 324 transfers the force of the spring 320 to a primary ring 326. The spring 320, retainer 322, disc 324, and primary ring 326 rotate with the sleeve 294 and apply pressure on the sleeve 294 in a direction away from the lip seal 308, thereby providing secure control of the sleeve 294 as it rotates with the shaft 242. The point of contact between the primary ring 326 and mating ring 316 is lubricated with oil 312, since the two rings 326, 316 move with respect to each other. The retainer 322 may fasten the primary ring 326 to the sleeve 294. An o-ring 328 may optionally be provided to further seal gas from the blower assembly 220 from escaping the chamber 299.

As one can discern from reading the above with reference to the figures, heated gas from the blower assembly 220 is effectively sealed in the chamber 299 through various o-rings, gasket 304 and oil 312. Thus, the gas remains stagnant and does not transfer heat from the blower assembly 220 to the o-rings. The shaft 242, however, may be thermally conductive and can transfer heat from the blower assembly 220 and a cooling effect from the portion of the shaft 242 adjacent the motor 246 to the seal assembly 280. Since the o-rings, and in particular o-ring 102 is closer to the blower assembly 220 than the motor 246 it could become heated especially in extreme temperature changes. However, the heat exchanger 300, transfers heat from the shaft 242 and sleeve 294 to the coolant 292, maintaining the o-rings, and in particular o-ring 302 at safe operating temperatures.

In use, the blower 210 includes the blower assembly 220 and seal assembly 280 joined to the blower assembly 220. The seal assembly 280 may further include at least one seal, such as O-rings 302, 328, gasket 304 or oil 312 and coolant 292, the coolant 292 being in thermal communication with at least a portion of the seal. The blower 210 can be positioned in two separate environments. The first environment may have a first temperature and containing a gas of a first type, but not the second type; and the second environment, having a second temperature and containing a gas of a second type, but not the first type.

For example, the preferred use of the blower 210 has the blower assembly 220 positioned in the first processor 130 where the temperature is at least 1000 degrees F. and most likely approximately 1200-1500 degrees F. and have a gas being combustible gas. The seal assembly 220 and motor 246 may be positioned in an environment where the temperature is no more than 100 degrees F. and the environmental gas is oxygenated. The shaft 242, rotatably joining the blower assembly 220 to the motor 246, may pass through both the first and second environments without the two environments intermixing. The seals preclude the gases from the environments from intermixing and the coolant 292 keeps the two environments at the preferred operating temperatures. (Note, mixing oxygen with the superheated combustible gas could cause undesired combustion and the motor 246 operates better at a temperature preferably at or below 100 degrees F.)

The coolant 292, which desirably is water, could be any thermally conductive flowable material such as anti-freeze and temperature adjusted gases. The coolant 292 may be in thermal communication with the seals, perhaps in a water jacket, such as coolant channel 286. Alternatively, the seal assembly may have any other heat exchanger 300 in thermal communication with the seals.

In operation, the motor 246 rotates the shaft 242, which rotates the fan blades 236. The seals, such as such as O-rings 302, 328, gasket 304 or oil 312, precludes commingling of gas from around the blower assembly 220 with that around the motor 246. Flowing coolant 292 in thermal communication with the seals maintains a temperature at which the seals do not degrade and remain operable. That is, placing a heat exchanger 300 in thermal communication with the seals keeps the seals at an operable temperature.

The blower has been described with reference to the drawings in a manner to fully disclose the best mode of making and using the present invention. Substantive and material changes may be made without departing from the spirit and scope of the present invention. For instance, the blower assembly 220 may be in a super cooled environment, instead of super heated, from which the motor may need to remain removed.

Detailed Description—Second Process/Processor

The second processor (a fuel processing device) 410 may include generating mechanism 420 and converting mechanism 430. The converting mechanism 430 may further include reducing mechanism 440, hydrogenating mechanism 450, a microwave 460, a catalyst 470 and a distillation apparatus 480. A flow chart, FIG. 12, is provided to show the various steps in the second process and such process is generally discussed throughout.

A suitable microwave 460, catalyst 470 and distillation apparatus 480 are described in the reference Thermal catalytic depolymerization (Rev. 15) Jan. 20, 2007, Bionic Microfuel Technologies, A.G. Such description is incorporated into this disclosure by reference. Each of these components will be described in serial fashion.

The generating mechanism 420, shown schematically in FIG. 13, produces feedstock 222, which may include activated carbon 424, char 426, coal 428 and/or other hydrogen deficient matter. Suitable generating mechanisms 420 include purchase of feedstock 422 on the open market. Production of feedstock 422 in the first processor 130 as described above. Production of feedstock 422 through manners described in the prior art, which is incorporated herein by reference, or manners known to those skilled in the art.

The reducing mechanism 440 of the converting mechanism 430 changes the feedstock 422 to a desired percentage of amorphous carbon 442. The activated carbon 424 is anticipated to be consistent throughout a batch 431 and may range from 100% amorphous to 100% crystalline and everything in between. Together the amorphous carbon 442 and crystalline carbon 444 preferably make up the totality of feedstock 422, e.g. 100%. The activated carbon 424 may be converted to amorphous carbon 442 allowing more complete hydrogenation. Accordingly, testing apparatus 446 may be provided for determining the percent concentration of amorphous carbon 442 and percent crystalline carbon 444 in a batch 431 of feedstock 422. Such testing apparatus may be X-ray crystallography, powder diffraction (SDPD) as disclosed in information by such companies as Inel, Rigaku MSC and Bede Scientific Instruments Ltd or performed in any other manner known to those skilled in the art.

The crystalline (activated) carbon 444 may need to be decrystallized or depolymerized, which may be done in the microwave 460 described below. Accordingly, the knowledge of percent amorphous carbon 442 versus crystalline carbon 444 may be used to determine the process, dwell time, and energy applied to the crystalline carbon 444 to yield a desired percentage of amorphous carbon 442 with the lowest expenditure of resources. The desired level of amorphous carbon 442 may be 100% or a lesser figure.

The reducing mechanism 440 may include the microwave 460 described below or may be heat from any source, chemical depolymerization/decrystallization and/or other manners known to those of ordinary skill in the art of producing amorphous carbon 429, including oxygen starved superheating.

The feedstock 422 has at least a useable portion that is devoid or substantially devoid of hydrogen atoms as is needed in the generation of diesel 490. Substantially devoid, refers to a deficiency of adequate proportion to preclude full formation of the hydrocarbons in diesel 490. Accordingly, the hydrogenating mechanism 450 joins hydrogen atoms to carbon atoms, while the carbon is in either a feedstock form 422, e.g., activated carbon 424, char 426, short hydrocarbon chains (natural gas) and/or coal 428 and have either an amorphous carbon 442 or crystalline carbon 444 structure, preferred is amorphous carbon 442. Such a chemical reaction is endothermic. The hydrogenating mechanism 450 may include a heat source 452 and hydrogen gas or any other suitable hydrogen source 454. The heat source 452 may take the form of the feedstock 422 being pre-heated to a temperature between 340° F. and 650° F. at any point between and including the generating mechanism 420 and microwave 460 or being heated by the microwave 460. While the feedstock 422 is heated to a temperature at or above 340° F., the feedstock 422 is subjected to the hydrogen gas 454. Carbon, hydrogen and combinations thereof are volatile at high temperatures, allowing the hydrogenation. Accordingly, the feedstock 422 may be maintained at a temperature at or below the flash point of carbon, preferably at or below 300 degrees C. and/or maintained in a non-oxygenated atmosphere.

For instance, where the generating mechanism 420 is the first processor 130 as described above, the activated carbon 424 in the vortex separator is at an elevated temperature and as such may be subjected to hydrogen 454 in a non-oxygenated atmosphere. As described below, the feedstock 422 in the microwave 460 is held at a sufficiently high temperature, 300° C. or perhaps higher, and may be subjected to hydrogen gas 454 at that point. The preferred point of positioning the hydrogenation mechanism 450 is at the microwave 460, since the feedstock 422 is reduced to amorphous carbon 442, rendering higher yields of hydrogenation an ultimately diesel fuel 490.

The microwave 460 operates in conjunction with a catalyst 470 in the presence of feedstock 422 and preferably in the presence of hydrogen gas 454. Accordingly, the microwave 460 and catalyst 470 is structure and adapted to polymerize hydrocarbons shorter than twelve hydrocarbons, reduce activated carbon 424 to amorphous carbon 442, hydrogenate activated carbon 424, char 426 and/or coal 428 while in an amorphous carbon 442 or crystalline carbon 444 structure, and break hydrogenated carbon chains at or around the twelve to fourteen carbon length. The reducing mechanism 440, hydrogenating mechanism 450 and microwave 460 can be separate units as indicated in FIG. 13 or be combined into a single unit within the microwave 460, with the combination being preferred. Through testing, the preferred operational perimeters are: frequency is 2.45 gigahertz, dwell time of one second to ten minutes, based on a preferred particle size of ¼ inch to ⅜ inch. The preferred catalyst 470 is zeolite (alumina-silicate).

The polymerization process may include true polymerization processes in which carbon atoms double bonded to other carbon atoms, such as may be found in activated carbon 424, have the double bond broken creating cites for attachment of another monomer. Polymerization may also include breaking the crystalline structure of activated carbon 424, rings and the like, temporarily forming elongated hydrocarbon chains of varying lengths, e.g., amorphous carbon 442.

The zeolite catalyst 470 responds to the microwave at a frequency of 2.45 gigahertz. At this point, the zeolite 470 polymerizes the feedstock 422, forming single bond carbon chains with the otherwise vacant bonding cites. At or above the temperature 250° C. hydrogen atoms from the hydrogen gas 454 join to the vacant bonding cites forming hydrogenated carbon chains. At a second temperature of 350° C., the zeolite 470 generally breaks the carbon chains at the 14 to 16 carbon length. The carbon length is believed to relate to the frequency of the microwave energy.

The microwave 460 applies energy to the feedstock 422, which may be coal 428, at a temperature at or about 300° C. Essentially, the catalyst 470 forms a temporary bond with the prepared feedstock 422. The catalyst 470, with applied energy shakes/vibrates, forming hydrogenated and elongated carbon chains. Eventually, the carbon chains reach such a length that the vibration of the catalyst 470 breaks the carbon chain. Through testing, it has been determined that the vast majority of the carbon chains were between 14 and 16 carbon atoms in length, which is high grade diesel fuel 490.

The microwave 460 does not simultaneously convert all feedstock 422 to diesel 490. Accordingly, a distillation process may be used to separate the various residue from the diesel 490. The distillation apparatus 480 may include a condenser 482, a thermometer 484 and containers 486. The high temperature feedstock 422 is above the evaporation point coming out of the microwave 460. The condenser 482 cools the gaseous feedstock 422. At various temperatures, condensation will form, indicating a quantity of a particular compound. Condensation that forms at 340° F.-650° F. degrees is diesel 490 and is directed to the containers 486. The distillation apparatus 480 is structured and adapted to separate hydrocarbon chains generally between twelve and fourteen carbons in length. Gases still yet to condense are generally short hydrocarbon chains to be recycled.

There are essentially two non-recycled by-products. The first is the desired diesel fuel 490, which is collected, cooled, packaged and delivered to a point of further distribution or use. The second by-product is residue 488. The residue 488 may include unreacted activated carbon 424 which maintains the mercuric sulfides and other inorganic compounds, a portion of the catalyst 470 and other inorganic compounds. The residue 488 is collected and disposed of according to lawful standards. Condensation that forms at alternate temperatures is generally shorter length hydrocarbon chains to be recycled back into an electrical generator 492, which may power the microwave 470.

Example 1

A sample was prepared according to the present disclosure. In particular, activated carbon was secured from a first processor 130. The sample of activated carbon was measured and weighted. Catalyst was added and the sample was transferred to a reactor flask. The flask was placed in a microwave reactor and processed at the desired temperature and dwell time. The resultant distilled diesel fuel had the characteristics that would meet or exceed ASTM D 975 standards. Meeting or exceeding ASTM D975 would allow the diesel fuel to be sold to the public.

The second processor 410 has been fully described with reference to the appended drawings and the best mode of making and using the present invention known at the time of filing. One can see that various modifications can be made without departing from the spirit and scope of the present invention as is set forth in the claims below.

CONCLUSION

The apparatus 10 and method associated therewith has been fully described above including the first processor 130, the blower 210 and the second processor 410 together with their respective manners of operation. In combination, these components 130, 210, and 410 process feedstock 12 into diesel fuel 14 and natural gas 16. Intermediary by-product, including natural gas 16 and activated carbon 18 may optionally be collected in user determined amounts. The description of the apparatus 10 and overall process has been supported by the descriptions of the first processor, the blower and the second processor.

The apparatus 10 has been described with reference to the appended drawings and the best mode of making and using the present invention known at the time of filing. One can see that various modifications, some of which have been mentioned can be made without departing from the spirit and scope of the present invention as is set forth in the claims below. 

The invention claimed is:
 1. A method of processing carbon-based feedstock into natural gas, the method comprising: introducing the carbon-based feedstock to a fluidized bed; flowing superheated non-oxygenated gas through the fluidized bed to the carbon-based feedstock at a velocity sufficient to separate natural gas and activated carbon from the feedstock; converting the carbon-based feedstock into natural gas and activated carbon; separating the natural gas from the activated carbon; and recycling a portion of the separated natural gas into the flow of superheated non-oxygenated gas, the recycled portion at least partially converting the carbon-based feedstock into the natural gas and the activated carbon.
 2. The method of claim 1 wherein the superheated non-oxygenated gas is heated to a temperature between 1000 degrees F. and 1500 degrees F.
 3. The method of claim 2 wherein the superheated non-oxygenated gas is heated to a temperature between 1000 degrees F. and 1200 degrees F.
 4. The method of claim 1 wherein the superheated non-oxygenated gas is natural gas.
 5. The method of claim 1, wherein the natural gas is medium BTU natural gas.
 6. The method of claim 1, comprising cooling a non-recycled portion of the natural gas.
 7. The method of claim 6, comprising compressing the cooled natural gas.
 8. The method of claim 1, wherein the flowing the superheated non-oxygenated gas through the fluidized bed comprises the converting the carbon-based feedstock into natural gas and activated carbon.
 9. The method of claim 1 further comprising the step of: allowing cleaning of the natural gas using the activated carbon to form clean natural gas, the cleaning starting at least as early as when the natural gas and activated carbon are leaving the fluidized bed and continuing through completion.
 10. The method of claim 1, wherein the recycled portion of the natural gas is a first portion, the method comprising: recycling a second portion of the natural gas into a burner, the burner using the second portion to superheat non-oxygenated gas for flowing through the fluidized bed.
 11. The method of claim 1 wherein the activated carbon is not charred though the process.
 12. The method of claim 11, wherein the method does not form ash.
 13. The method of claim 1, comprising: adjusting a velocity of the superheated non-oxygenated gas such that a flow of superheated non-oxygenated gas is slow enough to leave the feedstock on the fluidized bed and fast enough to separate the activated carbon and natural gas.
 14. The method of claim 1 comprising allowing cleaning of the natural gas using the activated carbon, the cleaning comprising the activated carbon removing harmful compounds from the natural gas to form clean natural gas.
 15. The method of claim 14, wherein allowing cleaning of the natural gas using the activated carbon comprises co-mingling the activated carbon and natural gas.
 16. The method of claim 14, wherein, removing harmful compounds from the natural gas includes removing at one least of mercury, chlorine, and sulfur compounds from the natural gas.
 17. The method of claim 14, wherein recycling a portion of the natural gas into the flow of superheated non-oxygenated gas comprises recycling a first portion of the cleaned natural gas, and the method comprising: recycling a second portion of the cleaned natural gas into a burner, the burner using the second portion to superheat non-oxygenated gas for flowing through the fluidized bed.
 18. The method of claim 1, wherein flowing superheated non-oxygenated gas through the fluidized bed comprises: vaporizing the natural gas from the carbon-based feedstock, the vaporizing converting a portion of the carbon-based feedstock into the activated carbon.
 19. The method of claim 1, wherein the velocity is sufficient to separate the natural gas and activated carbon from the feedstock based on the densities of the natural gas and activated carbon.
 20. The method of claim 1, where the velocity is sufficient to maintain the carbon-based feedstock on the fluidized bed. 